Aerosol delivery device and a related method

ABSTRACT

The present disclosure relates to an aerosol delivery device and a related method. The aerosol delivery device includes a heating chamber having an aerosol precursor composition disposed therein. A microwave radiation emitting device is operably engaged with the heating chamber and is configured to heat the aerosol precursor composition therein with the microwave radiation to form an aerosol from the aerosol precursor composition. An outlet port is formed in a housing of the aerosol delivery device and is in fluid communication with the heating chamber. The heating chamber is responsive to a suction applied to the outlet port for the aerosol to be drawn through the outlet port outwardly from the housing.

FIELD OF THE DISCLOSURE

The present disclosure relates to aerosol delivery devices, and moreparticularly to a microwave radiation heating element configured to heatan aerosol precursor composition, made or derived from tobacco orotherwise incorporating tobacco-related material, to form an inhalablesubstance for human consumption.

BACKGROUND

Smoking devices have been proposed through the years as improvementsupon, or alternatives to, smoking products that require combustingtobacco for use. Many of those devices purportedly have been designed toprovide the sensations associated with cigarette, cigar, or pipesmoking, but without delivering considerable quantities of incompletecombustion and pyrolysis products that result from the burning oftobacco.

To this end, there have been proposed smoking products, flavorgenerators, and medicinal inhalers that utilize electrical energy tovaporize or heat a volatile material, or attempt to provide thesensations of cigarette, cigar, or pipe smoking without burning tobaccoto a significant degree. See, for example, the various alternativesmoking articles, aerosol delivery devices and heat generating sourcesset forth in the background art described in U.S. Pat. No. 8,881,737 toCollett et al. and U.S. Pat. No. 7,726,320 to Robinson et al., U.S. Pat.App. Pub. Nos. 2013/0255702 to Griffith, Jr. et al.; 2014/0000638 toSebastian et al.; and 2014/0096781 to Sears et al., which areincorporated herein by reference.

Of these smoking products, flavor generators, and medicinal inhalersthat employ electrical energy to produce heat for smoke or aerosolformation, a wick and coil arrangement is often utilized in conjunctionwith an electrical power source, such as a battery. More particularly,in this arrangement, the coil is in direct contact with the wick andacts as a heating element. The coil is configured to conduct electricalcurrent from the battery, and heat, by direct contact, a limitedquantity of aerosol precursor composition absorbed by the wick. However,a wick and coil arrangement may cause thermal degradation of the aerosolprecursor composition since direct heating may result in uneven heatingof the aerosol precursor composition.

Accordingly, it is desirable to provide an aerosol delivery device thatemploys heat produced by an external energy source to heat an aerosolprecursor composition to provide the sensations of cigarette, cigar, orpipe smoking, which preferably does so without direct contact with orthermal degradation of the aerosol precursor composition, in order toprolong the service life of the device and deliver a more consistentaerosol.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure relates to aerosol delivery devices configured toproduce aerosol for human consumption. In one aspect, an aerosoldelivery device comprises a heating chamber having an aerosol precursorcomposition disposed therein, a microwave radiation emitting deviceoperably engaged with the heating chamber, and configured to heat theaerosol precursor composition therein with the microwave radiation, toform an aerosol from the aerosol precursor composition, and a housinghaving an outlet port and being in fluid communication with the heatingchamber, the heating chamber being responsive to a suction applied tothe outlet port for the aerosol to be drawn through the outlet portoutwardly from the housing.

In another aspect, a method of making an aerosol delivery devicecomprises operably engaging a microwave radiation emitting device with aheating chamber configured to receive an aerosol precursor compositiontherein, the microwave radiation emitting device being configured toheat the aerosol precursor composition with microwave radiation emittedthereby to form an aerosol from the aerosol precursor composition, andengaging the heating chamber with a housing having an outlet port suchthat the outlet port is in fluid communication with the heating chamber,and such that the heating chamber is responsive to a suction applied tothe outlet port for the aerosol to be drawn through the outlet portoutwardly from the housing.

BRIEF DESCRIPTION OF THE FIGURES

Having thus described the disclosure in the foregoing general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 illustrates a side view of an aerosol delivery device including amicrowave radiation emitting device according to an example embodimentof the present disclosure;

FIG. 2A illustrates a cross-sectional view of an aerosol produced in aheating chamber of an aerosol delivery device from microwave radiationgenerated by a microwave radiation emitting device according to anexample embodiment of the present disclosure;

FIG. 2B illustrates a cross-sectional view of aerosol produced in twoheating chambers of an aerosol delivery device from microwave radiationgenerated by a microwave radiation emitting device according to anexample embodiment of the present disclosure;

FIG. 3 illustrates a cross-sectional view of aerosol precursorcompositions in two different reservoirs of an aerosol delivery deviceaccording to an example embodiment of the present disclosure;

FIGS. 4A-C illustrate aerosol precursor processing devices according toexample embodiments of the present disclosure; and

FIG. 5 illustrates a flow diagram of a method of making an aerosoldelivery device according to example embodiments of the presentdisclosure.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present disclosure will now be described more fully hereinafter withreference to exemplary embodiments thereof. These exemplary embodimentsare described so that this disclosure will be thorough and complete, andwill fully convey the scope of the disclosure to those skilled in theart. Indeed, the disclosure may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. As used in the specification, andin the appended claims, the singular forms “a”, “an”, “the”, includeplural referents unless the context clearly dictates otherwise.

The present disclosure relates to aerosol delivery devices that usemicrowave radiation to heat a material (preferably without combustingthe material to any significant degree) to form an inhalable substance.In some aspects, the aerosol delivery devices are considered “table top”devices, similarly configured in size, shape, etc., to that of aconventional hookah. However, in other aspects, the aerosol deliverydevices are considered “hand-held” devices and are sized, shaped, etc.,to be easily held in the hands of consumers.

In certain preferred embodiments, the aerosol delivery devices arecharacterized as smoking articles. As used herein, the term “smokingarticle” is intended to mean an article or device that provides some orall of the sensations (e.g., inhalation and exhalation rituals, types oftastes or flavors, organoleptic effects, physical feel, use rituals,visual cues such as those provided by visible aerosol, and the like) ofsmoking a cigarette, cigar, or pipe, without any substantial degree ofcombustion of any component of that article or device. As used herein,the term “smoking article” does not necessarily mean that, in operation,the article or device produces smoke in the sense of the aerosolresulting from by-products of combustion or pyrolysis of tobacco, butrather, that the article or device yields vapors (including, e.g.,vapors within aerosols that can be considered to be visible aerosolsthat might be considered to be described as smoke-like) resulting fromvolatilization or vaporization of certain components of the article ordevice. In some preferred embodiments, the articles or devicescharacterized as smoking articles incorporate tobacco and/or componentsderived from tobacco.

In various aspects, articles or devices of the present disclosure arealso characterized as being vapor-producing articles, aerosol deliveryarticles, or medicament delivery articles. Thus, such articles ordevices are adapted so as to provide one or more substances (e.g.,flavors and/or pharmaceutical active ingredients) in an inhalable formor state. For example, inhalable substances are substantially in theform of a vapor (i.e., a substance that is in the gas phase at atemperature lower than its critical point). Alternatively, inhalablesubstances are in the form of an aerosol (i.e., a suspension of finesolid particles or liquid droplets in a gas). For purposes ofsimplicity, the term “aerosol” as used herein is meant to includevapors, gases, and aerosols of a form or type suitable for humaninhalation, whether or not visible, and whether or not of a form thatmight be considered to be smoke-like.

In use, smoking articles of the present disclosure are subjected to manyof the physical actions employed by an individual in using a traditionaltype of smoking article (e.g., a cigarette, cigar, or pipe that isemployed by lighting and inhaling tobacco). For example, the user of asmoking article of the present disclosure manipulates that article muchlike a traditional type of smoking article, draws on one mouthpieceelement of that article for inhalation of aerosol produced by thatarticle, takes puffs at selected intervals of time, etc.

Smoking articles of the present disclosure comprise some combination ofa heat source (i.e., a microwave radiation-emitting element), at leastone control component (e.g., arrangement for actuating, controlling,regulating and/or ceasing power to the heat source for controlling heatgeneration, such as by controlling microwave radiation emitted from theheat source to other components of the smoking article), an aerosolprecursor composition (e.g., commonly a liquid capable of yielding anaerosol upon application of sufficient heat, such as ingredientscommonly referred to as “smoke juice,” “e-liquid” and “e-juice”), and amouthpiece element for allowing draw upon the smoking article (otherwisereferred to herein as an aerosol delivery device) for aerosol inhalation(e.g., a defined air flow path through the smoking article such thataerosol generated can be withdrawn therefrom upon draw).

One example embodiment of an aerosol delivery device 100 is provided inFIG. 1. As seen in the side view illustrated therein, the aerosoldelivery device 100 comprises a housing 102 and an enclosure 104 thatare either permanently or detachably connected in a functioningrelationship. The enclosure 104 is configured in size and/or shape tofit around a first portion of the housing 102 and to substantiallyenclose the first portion of the housing 102 therein. In some instances,the first portion is a lower portion or base of the housing 102. Forexample, the enclosure 104 is molded to correspond to external contoursof the first portion of the housing 102 and is hinged to open and close.In this manner, the first portion of the housing 102 is fit into themolded contour of the enclosure 104 when the enclosure is hingedlyopened and is fixedly retained within when the enclosure is hingedlyclosed. Other types of engagement or connection between the housing 102and the enclosure 104 are also contemplated.

In one embodiment, a heating chamber 106 configured to receive anaerosol precursor composition 108 therein defines the first portion ofthe housing 102. In some aspects, the enclosure 104 substantiallysurrounds or encloses the heating chamber 106. The heating chamber 106is a single heating chamber or, in some embodiments, is divided intofurther sub-chambers. For example, in one embodiment as illustrated inFIG. 1 and in more detail in FIG. 2A, a single heating chamber 106 isprovided. In another example, as another embodiment illustrated in FIG.2B, a first heating sub-chamber 106A and a second heating sub-chamber106B are provided. In such instances, one of the first and secondheating sub-chambers 106A-B is configured as having a greater capacityfor the aerosol precursor composition 108 than the other sub-chamber. Inthe example illustrated in FIG. 2B, the second heating sub-chamber 106Bhas a greater capacity for the aerosol precursor composition 108 thanthe first heating sub-chamber 106A. In other such instances, the firstand second heating sub-chambers 106A-B are configured as having asubstantially similar capacity for the aerosol precursor composition108.

In either instance, the heating chamber 106 is operably engaged with aheat source, such as a microwave radiation emitting device 110. Themicrowave radiation emitting device 110 comprises, in some aspects, amagnetron that generates microwave radiation 112. In some aspects, themagnetron is preferably sized to conform to a desired shape, size, etc.,of the aerosol delivery device 100 so that the device is easilymanipulated, without detracting from a desirable smoking experience. Inother aspects, the microwave radiation emitting device 110 comprises anantenna, coils, or the like, configured to generate the microwaveradiation 112. In such cases the material to be heated may reside indifferent arrangement/orientation with respect to the microwave source.For example in the case of a coil, the material may reside in theinterior (center) of the coil.

As such, the microwave radiation 112 emitted by the microwave radiationemitting device 110 is configured to penetrate the heating chamber 106and heat the aerosol precursor composition 108 disposed therein in orderto form an aerosol 114 therefrom. More particularly, in some aspects,the microwave radiation 112 induces polar molecules of the aerosolprecursor composition 108 to rotate and produce thermal energy.Consequently, the molecules in the aerosol precursor composition areexcited and heated by the microwave radiation 112 in a uniform manner sothat minimal thermal degradation (i.e., there are no superheatedparticles) of the aerosol precursor composition 108 occurs upon theformation of the aerosol 114, and the resulting aerosol 114 has a moreconsistent vapor chemistry than that produced by other types of heatsources, such as electric heating elements (e.g., a resistive heatingcoil).

In some aspects, the microwave radiation emitting device 110, as well asother aspects of the aerosol delivery device 100, itself, iselectrically powered by a power source. The power source is configuredto provide power, energy, or current flow sufficient to provide variousfunctionalities of the aerosol delivery device 100, such as heating ofthe aerosol precursor composition via the microwave radiation emittingdevice 110, powering of control components or systems, powering ofindicators, and the like. Preferably, the power source can take onvarious embodiments that are each capable of delivering sufficient powerto the microwave radiation emitting device 110 to rapidly heat theaerosol precursor composition 108 received in the heating chamber 106for forming the aerosol therefrom, and to power other components of theaerosol delivery device 100 through use for the desired duration oftime. For example, in some instances, the aerosol delivery device 100,including the microwave radiation emitting device 110, is powered via astandard household outlet (e.g., 120 AC volts). In another example, theaerosol delivery device 100 is powered by a battery of a sufficientenergy density. Therefore, when the aerosol delivery device 100 isconnected to a power source, the microwave radiation emitting device 110is powered and controllable to heat the aerosol precursor composition108 disposed in the heating chamber 106.

The housing 102, the enclosure 104, and/or the heating chamber 106 areconfigured such that the microwave radiation 112 emitted by themicrowave radiation emitting device 110 is contained therein. Forexample, the housing 102, the enclosure 104, and/or the heating chamber106 are similar in materials and design to a Faraday cage to prevent themicrowave radiation from escaping or leaking out. Any outlet port ororifice extending through a surface of the housing 102, the enclosure104, and/or the heating chamber 106, and in fluid communication with anexterior of the housing 102 or enclosure 104, includes a shieldingelement 116 to contain the microwave radiation 112 within the aerosoldelivery device 100. In these aspects, the housing 102 of the aerosoldelivery device 100 defines the outlet port 118, and the outlet port 118is in fluid communication with the heating chamber 106. As such, ashielding element 116 is engaged with the outlet port 118. An airflowchannel 120 defined within the housing 102 and/or the enclosure 104 alsoincludes a shielding element 116. The shielding element 116 comprises atleast one layer of a conductive material (e.g., an aluminum mesh),although other materials, types, and/or configurations of a shieldingelement 116 are contemplated.

The outlet port 118 is configured to receive suction (i.e., from aconsumer) at a mouthpiece element 122, such that the aerosol 114 isdrawn through the outlet port 118 outwardly from the housing 102 inresponse to the suction. A hose member 124 is engageable with the outletport 118. As illustrated in FIG. 1, for example, a proximal end of thehose member 124 is engaged with the outlet port 118 and an opposingdistal end is engaged with the mouthpiece element 122. In this manner,the mouthpiece element 122 and the hose member 124 are in fluidcommunication with the heating chamber 106 via the outlet port 118 so asto receive the aerosol 114 therefrom in response to suction applied tothe mouthpiece element 122. In some aspects, there is more than oneoutlet port 118. For example and as illustrated in FIG. 1, there are atleast two outlet ports 118. In such instances, a hose member 124 with amouthpiece element 122 is engaged with each available outlet port 118 ofthe housing 102, such that multiple consumers are able to use theaerosol delivery device 100 at one time. Otherwise, unused outlet portsare configured to be capped or blocked off to prevent the aerosol fromescaping from the housing 102 therethrough or otherwise from enteringand diluting the aerosol in the housing 102.

In some aspects, the one or more heating sub-chambers 106A-B areconfigured to be selectively in fluid communication with a respectiveoutlet port 118. For example, a selector element (e.g., a valve, flange)disposed within the one or more heating sub-chambers 106A-B isconfigured to be automatically responsive to the suction applied throughthe outlet port 118 to direct the aerosol 114 through the outlet port118 from a respective heating sub-chamber 106A-B. FIG. 2A illustratessuch an example, where the selector element is responsive or opens thesecond heating sub-chamber 106B in response to suction applied through arespective outlet port. In FIG. 2A, for example, as the outlet portthrough which suction is applied is not engaged with the first heatingsub-chamber 106A, the selector element is nonresponsive or closed, suchthat no aerosol 114 is directed therefrom.

In other examples, the selector element is configured to be manuallyresponsive to user selection. In these instances, a switch, button,lever, or any other mechanism is usable to selectively control fromwhich heating sub-chamber 106A-B the aerosol 114 is directed.

The airflow channel 120 is configured to allow airflow between theheating chamber 106 and ambient air external to the housing 102 and/orthe enclosure 104. For example, as illustrated in FIG. 1 and in moredetail in FIG. 2A, a single heating chamber 106 has an airflow channel120 extending from an interior of the heating chamber 106, through aninterior of the enclosure 104, and out to an exterior of the housing102. In another example, as illustrated in FIG. 2B, the two heatingchambers 106A-B each have an individual airflow channel 120A-B extendingtherefrom to the exterior of the housing 102. However, in other examples(not shown), the airflow channels 120A-B are configured to extend from arespective heating chamber 106A-B and combine into one channel withinthe enclosure 104, with the one channel extending to the exterior of thehousing 102. In instances where there is more than one airflow channel120, there is a shielding element 116A-B associated with each channel.

Referring back to FIG. 1, an aerosol precursor delivery arrangement 126is in operable engagement with the heating chamber 106 and is configuredto deliver the aerosol precursor composition 108 to the heating chamber106 from a reservoir 128. The aerosol precursor delivery arrangement 126is, in various aspects, an internal flow tube, a passageway or othermechanism. As illustrated in FIG. 1, for example, the aerosol precursordelivery arrangement 126 is an airflow passageway defined within aninterior of the housing 102 and configured to direct, by gravity, theaerosol precursor composition 108 dispensed from the reservoir 128through the housing 102 to the heating chamber 106.

In other aspects, the aerosol precursor delivery arrangement 126 is alsoan aerosol delivery arrangement, such that an aerosol formed by thecombination of the vaporization of the aerosol precursor composition 108and the ambient air in the heating chamber 106, is delivered to theconsumer via the same mechanism that transports the aerosol precursorcomposition 108 to the heating chamber 106. In these aspects, theairflow passageway 126 is configured with an interior volume larger thanthat of the heating chamber 106 in order to provide a headspace for theproduced aerosol to expand and/or age therein. In other aspects, notshown, the airflow passageway 126 is configured as a flow tube engagedbetween the reservoir 128 and the heating chamber 106 in order totransport the aerosol precursor composition 108 to the heating chamber106 from the reservoir 128, as well as to provide a headspace for theproduced aerosol to expand therein. Other similar mechanisms fordelivering the aerosol precursor composition 108 and/or the producedaerosol are also contemplated.

The reservoir 128 is configured to contain the aerosol precursorcomposition 108 therein and is configured to be in fluid communicationwith the aerosol precursor delivery arrangement 126. FIG. 1 illustratesa reservoir 128 configured to contain a first aerosol precursorcomposition 108. However, in some aspects as illustrated in FIG. 3,there are two or more reservoirs 128A-B, each reservoir 128A-B beingconfigured to contain a distinct aerosol precursor composition 108A-Btherein, wherein each of the two or more reservoirs 128A-B is in fluidcommunication with the aerosol precursor delivery arrangement 126 andco-operable therewith.

In some aspects, for example, each of the two or more reservoirs 128A-Bcontains different aerosol precursor compositions 108A-B therein. Insuch instances, a manual or automatic actuation mechanism (not shown) isprovidable for selectively actuating fluid communication between one ormore of the reservoirs 128A-B and the aerosol precursor deliveryarrangement 126.

In other aspects, for example, each of the two or more reservoirs 128A-Bcontain a same or substantially similar aerosol precursor compositions108A-B, wherein a first of the two or more reservoirs 128A is a primaryreservoir and a second of the two or more reservoirs 128B is a secondaryreservoir. In this instance, the first or primary reservoir 128A isconfigured to be in fluid communication with the aerosol precursordelivery arrangement 126, while the second or secondary reservoir 128Bis configured to be in fluid communication with the aerosol precursordelivery arrangement 126 only upon depletion of the aerosol precursorcomposition 108A contained within the first reservoir 128A. A manual orautomatic actuation mechanism (not shown) is providable in theseinstances in order to sense depletion of the aerosol precursorcomposition 108A contained within the first reservoir 128A and actuatefluid communication between the second reservoir 128B containing theaerosol precursor composition 108B and the aerosol precursor deliveryarrangement 126.

The aerosol precursor delivery arrangement 126 is thereby configured todeliver either individually or in combination any of the distinctaerosol precursor compositions 108A-B from the respective one of the twoor more reservoirs 128A-B to the heating chamber 106. For example, twodifferent aerosol precursor compositions 108A-B contained withinrespective reservoirs 128A-B are simultaneously, but independently,delivered to respective heating sub-chambers 106A-B. In such aninstance, each reservoir 128A-B is in fluid communication with anindividual aerosol precursor delivery arrangement, heating chamber, andoutlet port. As a result of such an arrangement, the aerosol deliverydevice 100 is configured to be customizable for each consumer, whenmultiple consumers are using the aerosol delivery device 100simultaneously, such that each consumer is able to choose his or her ownaerosol precursor composition 108 (e.g., a menthol, a crema, etc.,) foran individualized experience.

In other such aspects, for example, two different aerosol precursorcompositions 108A-B contained within the respective reservoirs 128A-Bare simultaneously delivered to a same heating chamber 106 such that thetwo different aerosol precursor compositions 108A-B are combinablewithin the heating chamber 106 prior to, during, and/or afteraerosolization. As a result of such an arrangement, the aerosol deliverydevice 100 is configured to be customizable for a single consumer ormultiple consumers, such that combinations of various aerosol precursorcompositions 108A-B result in a unique experience.

The reservoir 128 is configured as either a reusable reservoir, or aremovable and disposable reservoir. In one example, the reservoir 128 isreusable such that additional quantities of the aerosol precursorcomposition 108 are added to the reservoir 128 when needed. In otherexamples, the reservoir 128 is removed upon use of all of the aerosolprecursor composition 108 contained within. A new reservoir 128containing additional quantities of an aerosol precursor composition isthen engaged with the housing 102, where the reservoir 128 is adisposable reservoir or a refillable and reusable reservoir. Regardless,the reservoir 128 is engageable with the housing 102 via a threadedengagement, a press-fit engagement, a magnetic engagement, etc.Otherwise, the reservoir 128 is fixedly engaged with the housing 102such that the reservoir 128 is unable to be removed from the housing 102(i.e., in the case of a refillable or a reusable reservoir). Regardless,the reservoir 128 is in fluid communication with the aerosol precursordelivery arrangement 126 such that the aerosol precursor composition(s)108 is delivered to the heating chamber(s) 106 therefrom.

In order to meter a quantity of the aerosol precursor composition(s) 108delivered to the heating chamber(s) 106, one embodiment of the reservoir128 comprises a screen 130 having a grid composition fine enough toprevent all of the aerosol precursor composition 108 from beingdelivered to the heating chamber 106 at one time, but large enough toallow the composition particles to flow through at a limited rate. Forexample, as illustrated in FIG. 1, the screen 130 is configured to spana substantial entirety or an entirety of an interior diameter of thehousing 102 and is disposed adjacent to the reservoir 128. In anotherexample, as illustrated in FIG. 3, the screen 130 is disposed adjacentto both reservoirs 128A-B; although a screen for each respectivereservoir 128A-B is also contemplated.

In some aspects, aerosol precursor composition 108, which may also bereferred to as a vapor precursor composition, comprises one or moredifferent components. The different components of the aerosol precursorcomposition 108 are selected from the group consisting of a liquid, agel, a solid, a capsule, a colloid, a suspension, a botanical, and acombination thereof interspersed in a porous matrix or in a discretepacket (e.g., substrate). In some non-limiting examples, one of thecomponents of the aerosol precursor composition 108 includes apolyhydric alcohol (e.g., glycerin, propylene glycol, or a mixturethereof). Representative types of further aerosol precursor compositionsare set forth in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr. et al.; U.S.Pat. No. 5,101,839 to Jakob et al.; PCT WO 98/57556 to Biggs et al.; andChemical and Biological Studies on New Cigarette Prototypes that HeatInstead of Burn Tobacco, R. J. Reynolds Tobacco Company Monograph(1988); the disclosures of which are incorporated herein by reference.

The components of the aerosol precursor composition 108 are combinedbased on particular effects each component lends to the overallexperience for the consumer. In some aspects, components that enable theaerosol delivery device 100 to provide some or all of the sensations(e.g., inhalation and exhalation rituals, types of tastes or flavors,organoleptic effects, physical feel, use rituals, visual cues such asthose provided by visible aerosol, and the like) of smoking a cigarette,cigar, or pipe are selected. In other aspects, components that enablethe aerosol delivery device 100 to produce a uniformly heated aerosol114 from the aerosol precursor composition 108 are also selected. Forexample, a component that prevents superheating of the aerosol precursorcomposition 108, such as inert, non-volatile granules (e.g., boilingchips) or other nucleation surfaces capable of absorbing excessmicrowave radiation 112, are selectable for the aerosol precursorcomposition 130. Alternatively, the controller element 132 is configuredto selectively control the microwave radiation emitting device 110 toemit microwave radiation 112 at a frequency specific to one or morecomponents of the aerosol precursor composition 108.

Some embodiments of the aerosol delivery device 100 include a controllerelement 132 in communication between the microwave radiation emittingdevice 110 and a sensing element 134 in communication with the aerosolprecursor composition 108 within the heating chamber 106. The controllerelement 132 comprises, in some aspects, a microcontroller. The sensingelement 134 comprises, in some aspects, a fiber optic probe. Asillustrated in FIG. 1 and in more detail in FIG. 2A, the controllerelement 132 is disposed within the enclosure 104 and the sensing element134 is disposed within the heating chamber 106. In another example, asillustrated in FIG. 2B, a single controller element 132 is incommunication between the microwave radiation emitting device 110 andboth sensing elements 134A and 134B disposed in respective heatingchambers 106A-B.

In some embodiments, the sensing element(s) 134 is configured to sense atemperature, airflow velocity, pressure, aerosol precursor compositionelements, or any combination thereof of the aerosol precursorcomposition 108 within the heating chamber 106. For example, where thesensing element 134 is configured to sense a temperature, the controllerelement 132 is responsive to the sensed temperature to regulate themicrowave radiation 112 to heat the aerosol precursor composition 108 toonly a maximum desired temperature. In this manner, the controllerelement 132 taken in conjunction with the sensing element(s) 134 isconfigured to prevent superheating, underheating, etc., of the aerosolprecursor composition 108.

In other embodiments, the sensing element(s) 134 is also configured tosense a volume of the quantity of aerosol precursor composition 108contained in the heating chamber 106. For example, where there are twoheating chambers 106A-B, the sensing elements 134A-B are each configuredto sense a capacity of the aerosol precursor composition 108 within arespective heating chamber 106A-B. The controller element 132 isresponsive to the sensed capacity to prevent the aerosol precursordelivery arrangement 126 from directing any more of the aerosolprecursor composition 108 to one or both of the heating chambers 106A-B,where one or both of the heating chamber 106A-B are at maximum capacity.As such, for example, a valve mechanism in communication with thecontroller element 132 is configured to limit a quantity of aerosolprecursor composition 108 delivered to one or both of the heatingchambers 106A-B. Alternatively, in instances where one of the heatingchambers 106A-B is at maximum capacity, the controller 132 is responsiveto the sensed maximum capacity of that chamber to direct the aerosolprecursor composition 108 to the other heating chamber 106A-B not atmaximum capacity.

Additionally, in various embodiments, an aerosol precursor compositiontransport element is disposed in the heating chamber 106 incommunication with the aerosol precursor composition 108. For exampleand as illustrated in FIGS. 2A-B, one embodiment of the aerosolprecursor composition transport element comprises a wick 136 formed froma variety of materials (e.g., cotton and/or fiberglass) configured totransport (i.e., absorb and wick) the aerosol precursor composition 108.Due to the material design of the wick, the wick 136 is configured toabsorb a limited quantity (i.e., puff size amount) of the aerosolprecursor composition 108 delivered to the heating chamber 106; the wickhaving the liquid absorbed thereby is then heated by the microwaveradiation emitting device 110 to produce an aerosol 114. Additionally,for example, a puff sized amount of the aerosol precursor composition108 is able to be pumped, dripped, or otherwise delivered to the heatingchamber 106 and onto the wick 136. However, implementation of the wick136 is optional.

Accordingly, in use, when a consumer draws on the mouthpiece element 122of the aerosol delivery device 100, a quantity of the aerosol precursorcomposition 108 is directed, by the aerosol precursor deliveryarrangement 126, from the reservoir 128 to the heating chamber 106.Alternatively, the aerosol precursor composition 108 is already disposedwithin the heating chamber 106 prior to the draw. The microwaveradiation emitting device 110 is then activated (e.g., such as via apuff sensor or sensing element 134) and the components of the aerosolprecursor composition 108 are vaporized or aerosolized within theheating chamber 106. In some aspects, the controller element 132 iscommunicatively connected with the microwave radiation emitting device110 to control the microwave radiation 112 emitted therefrom. Forexample, where the sensing element 134 senses an aerosol precursorcomposition 108 within the heating chamber 106 requiring increasedmicrowave radiation 112 to aerosolize (e.g., due to a temperature,volume, pressure, etc., of the aerosol precursor composition), thecontroller element 132 is able to control the microwave radiationemitting device 110 to emit microwave radiation 112 sufficient toaerosolize the aerosol precursor composition 108.

Drawing upon the mouthpiece element 122 of the aerosol delivery device100 also causes ambient air to enter the airflow channel 120 and passinto the heating chamber 106. The drawn ambient air combines with theformed vapor/aerosol within the heating chamber 106 and/or the aerosoldelivery arrangement 126 to transport an aerosol 114. The formed aerosol114 is drawn from the heating chamber 106, passes through the aerosoldelivery arrangement 126, out the outlet port 118, through the hosemember 124, and out the mouthpiece element 122 of the device 100. Insome aspects, any aerosol 114 that is not drawn though the outlet port118 resides or remains within the aerosol delivery arrangement 126,where it is aged.

An exemplary mechanism that provides puff-actuation capability includesa Model 163PC01D36 silicon sensor, manufactured by the MicroSwitchdivision of Honeywell, Inc., Freeport, Ill. Still further components areoptionally utilized in the aerosol delivery device 100 of the presentdisclosure. For example, U.S. Pat. No. 5,261,424 to Sprinkel, Jr.discloses piezoelectric sensors that can be associated with themouth-end of a device to detect user lip activity associated with takinga draw and then trigger heating; U.S. Pat. No. 5,372,148 to McCaffertyet al. discloses a puff sensor for controlling energy flow into aheating load array in response to pressure drop through a mouthpiece;U.S. Pat. No. 5,967,148 to Harris et al. discloses receptacles in asmoking device that include an identifier that detects a non-uniformityin infrared transmissivity of an inserted component and a controllerthat executes a detection routine as the component is inserted into thereceptacle; U.S. Pat. No. 6,040,560 to Fleischhauer et al. describes adefined executable power cycle with multiple differential phases; U.S.Pat. No. 5,934,289 to Watkins et al. discloses photonic-optroniccomponents; U.S. Pat. No. 5,954,979 to Counts et al. discloses means foraltering draw resistance through a smoking device; U.S. Pat. No.6,803,545 to Blake et al. discloses specific battery configurations foruse in smoking devices; U.S. Pat. No. 7,293,565 to Griffen et al.discloses various charging systems for use with smoking devices; U.S.Pat. No. 8,402,976 by Fernando et al. discloses computer interfacingmeans for smoking devices to facilitate charging and allow computercontrol of the device; U.S. Pat. No. 8,689,804 by Fernando et al.discloses identification systems for smoking devices; and WO 2010/003480by Flick discloses a fluid flow sensing system indicative of a puff inan aerosol generating system; all of the foregoing disclosures beingincorporated herein by reference in their entireties.

Further description of other control components, includingmicrocontrollers that can be useful in the present smoking article, areprovided in U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,875, all toBrooks et al., U.S. Pat. No. 5,372,148 to McCafferty et al., U.S. Pat.No. 6,040,560 to Fleischhauer et al., and U.S. Pat. No. 7,040,314 toNguyen et al., all of which are incorporated herein by reference intheir entireties.

FIGS. 4A-4C illustrate schematics of exemplary aerosol precursorprocessing units. An aerosol precursor processing unit is configured topre-heat the aerosol precursor composition 108 prior to aerosolizationof the aerosol precursor composition 108 by the device 100.Alternatively, the aerosol precursor processing unit is configured toprocess the aerosol precursor composition 108 after pre-heating of theaerosol precursor composition 108 by the device 100.

Referring to FIG. 4A, an aerosol precursor processing unit 400A isillustrated. The aerosol precursor processing unit 400A is configured tobe in fluid communication with the heating chamber(s) 106. Moreparticularly, the aerosol precursor processing unit 400A is configuredto deliver the processed aerosol precursor composition to the heatingchamber(s) via an outlet (not shown) communicating with the heatingchamber(s) 106, through the airflow channel (e.g., 120, FIGS. 2A-B), orthrough the aerosol precursor delivery arrangement (e.g., 126, FIG. 1).The aerosol precursor processing unit 400A is configured to pre-heat theaerosol precursor composition 108 to a pre-heat temperature, thepre-heat temperature being less than a maximum desired temperature forforming the aerosol from the aerosol precursor composition 108, prior tothe processed (i.e., pre-heated) aerosol precursor composition beingdelivered to the heating chamber(s) 106. Alternatively, the aerosolprecursor composition 108 is pre-heated in the heating chamber(s) 106 ofthe aerosol delivery device 100 and removed from the heating chamber(s)106 prior to vaporization/aerosolization of the aerosol precursorcomposition 108. At this point, the pre-heated aerosol precursorcomposition 108 is delivered (e.g., via the aerosol precursor deliveryarrangement 126) to the aerosol precursor processing unit 400A andvaporized. Ambient air provided via an inlet (not shown) in the aerosolprecursor processing unit 400A combines with the vaporized/aerosolizedaerosol precursor composition transports the aerosol to be consumed by auser.

In some aspects, the aerosol precursor processing unit 400A comprises aheating element or an aerosol forming element configured to interactwith the aerosol precursor composition provided therein. In one example,a heating element comprises a hot plate. In another example, a heatingelement comprises a coil heater 402. The coil heater 402 is configuredas a resistive heating element that produces heat when electricalcurrent is applied therethrough. Example materials from which theheating element 402 is formed include Kanthal (FeCrAl), Nichrome,molybdenum disilicide (MoSi₂), molybdenum silicide (MoSi), molybdenumdisilicide doped with aluminum (Mo(Si,Al)₂), and ceramics (e.g., apositive temperature coefficient ceramic). In order to produce heat, theheating element 402 comprises conductive heater terminals (e.g.,positive and negative terminals) that are configured to direct currentflow through the heating element 402 and also for attachment toappropriate wiring or circuitry (not illustrated) to form an electricalconnection of the heating element 402 with a battery or other electricalpower source. In other non-limiting examples, the heating element 402 isnon-electric and produces heat for vaporizing the aerosol precursorcomposition 108 via conduction, convection, and/or radiation.

In other aspects, the aerosol precursor processing unit 400A comprises amicrowave radiation emitting device that is configured to interact withthe aerosol precursor composition provided therein and pre-heat theaerosol precursor composition using emitted microwave radiation.

A sensing element 404 provided within the aerosol precursor processingunit 400A is configured to sense when the aerosol precursor composition108 has been heated by the heating element 402 to the pre-heattemperature. The electrical connection with the heating element 402 isdisengaged after the sensing element 404 senses that the pre-heattemperature is reached. Additionally, where the aerosol precursorcomposition is pre-heated in the heating chamber(s) 106 of the device100, the sensing element 404 is configured to sense when a maximumtemperature is reached and the heating element 402 is, subsequently,disengaged.

Referring now to FIG. 4B, an aerosol precursor processing unit 400B isillustrated. The aerosol precursor processing unit 400B is configured tobe in fluid communication with the heating chamber(s) 106. Moreparticularly, the aerosol precursor processing unit 400B is configuredto deliver the processed aerosol precursor composition to the heatingchamber(s) 106 via an outlet (not shown) communicating with the heatingchamber(s) 106, through the airflow channel (e.g., 120, FIGS. 2A-B), orthrough the aerosol precursor delivery arrangement (e.g., 126, FIG. 1).The aerosol precursor processing unit 400B is configured to pre-heat asubstrate material 406 having the aerosol precursor composition 108associated therewith to a pre-heat temperature, the pre-heat temperaturebeing less than a maximum desired temperature for forming the aerosolfrom the aerosol precursor composition 108, prior to the pre-heatedsubstrate material 406 being delivered to the heating chamber 106.

In some aspects, the aerosol precursor processing unit 400B comprises aconventional microwave oven. The aerosol precursor processing unit 400B,thus, pre-heats the substrate 406 to the pre-heat temperature using thecontrol and/or sensing components provided in conventional microwaveovens. The pre-heated substrate 406 is then delivered to the heatingchamber 106 for aerosolization via further microwave radiation.Alternatively, the substrate 406 is delivered to the reservoir 128 andthe aerosol precursor delivery arrangement 126 delivers limitedquantities thereof to the heating chamber 106.

FIG. 4C illustrates an aerosol precursor processing unit 400C. Theaerosol precursor processing unit 400C is configured to be in fluidcommunication with the heating chamber(s) 106. More particularly, theaerosol precursor processing unit 400C is configured to deliver theprocessed aerosol precursor composition to the heating chamber(s) 106via an outlet (not shown) communicating with the heating chamber(s) 106,through the airflow channel (e.g., 120, FIGS. 2A-B), or through theaerosol precursor delivery arrangement (e.g., 126, FIG. 1). The aerosolprecursor processing unit 400C is configured to pre-heat a membrane 408comprising the aerosol precursor composition 108 to a pre-heattemperature, the pre-heat temperature being less than a maximum desiredtemperature for forming the aerosol from the aerosol precursorcomposition 108, prior to the pre-heated membrane 408 being delivered tothe heating chamber 106.

In some aspects, the aerosol precursor processing unit 400C comprises aconventional microwave oven, while the membrane 408 comprises a singleor a multi-use membrane. In one example, the aerosol precursorcomposition 108 is provided in the membrane 408; the membrane 408 issealed, and then provided to the aerosol precursor processing unit 400C.The aerosol precursor processing unit 400C, thus, pre-heats the membrane408 to the pre-heat temperature using the control and/or sensingcomponents provided in conventional microwave ovens. The membrane 408 isprovided to the aerosol precursor processing unit 400C in a deflatedstate, but transitions to an inflated state as the aerosol precursorcomposition 108 within is vaporized/aerosolized. The pre-heated,inflated membrane 408 is then able to be puffed on via a mouthpieceattachment or otherwise attached to the aerosol delivery device 100 inorder to allow the aerosol to be delivered to a consumer in a controlledmanner. After delivery of the aerosol, the membrane 408 is eitherdisposed of (i.e., single-use) or is unsealed and an additional quantityof the aerosol precursor composition 108 is disposed within (i.e.,multi-use).

In a further embodiment, not illustrated, the aerosol delivery device100 is utilized to further evaporate an aerosol produced by anothermechanism. More particularly, the microwave radiation emitting device110 is configured to reduce in size aerosol particles produced by othermechanisms in order to make the particles small enough (e.g., 2 micronsin diameter) for inhalation. Some such mechanisms for producing anaerosol include ink jet spray devices, which, in various embodiments,are configured to spray aerosol particles within an interior of theheating chamber 106 of the aerosol delivery device 100. For example, athermal printer or a bubble jet printer is capable of spraying anaerosol particle approximately 4-40 microns in diameter, while apiezoelectric printer is capable of spraying an aerosol particleapproximately 1-2 microns in diameter. As an aerosol comprised ofparticles larger than 2 microns is generally not conveniently inhalable,the sprayed aerosols are further evaporated by the microwave radiationemitting device 110 to reduce the size of the particles to an inhalablediameter, for example 2 microns or less.

Alternatively, a wick and/or coil arrangement is provided within aninterior of the heating chamber 106 to produce an aerosol comprised ofparticles having individual diameters between approximately 200-500nanometers. While an aerosol comprising particles of this diameter isinhalable, in some embodiments, the microwave radiation emitting device110 is configured to further vaporize/aerosolize the aerosol 114.

Referring now to FIG. 5, a method of making an aerosol delivery deviceis illustrated. The method, generally designated 500, is utilized tomake an aerosol delivery device that produces an aerosol by microwaveradiation of a precursor composition, such as the one described above.

In step 502, a microwave radiation emitting device (e.g., 110, FIG. 1)is operably engaged with a heating chamber (e.g., 106, FIG. 1)configured to receive an aerosol precursor composition (e.g., 108,FIG. 1) therein. In some embodiments, the microwave radiation emittingdevice is configured to heat the aerosol precursor composition withmicrowave radiation emitted thereby to form an aerosol from the aerosolprecursor composition. An aerosol precursor composition is disposed in aheating chamber

In step 504, the heating chamber is engaged with a housing (e.g., 102,FIG. 1) having an outlet port (e.g., 118, FIG. 1) such that the outletport is in fluid communication with the heating chamber, and such thatthe heating chamber is responsive to a suction applied to the outletport for the aerosol to be drawn through the outlet port outwardly fromthe housing.

Many modifications and other embodiments of the disclosure will come tomind to one skilled in the art to which this disclosure pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that thedisclosure is not to be limited to the specific embodiments disclosedherein and that modifications and other embodiments are intended to beincluded within the scope of the appended claims. Although specificterms are employed herein, they are used in a generic and descriptivesense only and not for purposes of limitation.

The invention claimed is:
 1. An aerosol delivery device, comprising: aheating chamber having an aerosol precursor composition disposedtherein; a microwave radiation emitting device comprising a magnetronextending at least partially about and operably engaged with the heatingchamber, the magnetron being configured to emit microwave radiation toheat the aerosol precursor composition therein with the microwaveradiation, to form an aerosol from the aerosol precursor composition;and a housing having an outlet port and being in fluid communicationwith the heating chamber, the heating chamber being responsive to asuction applied to the outlet port for the aerosol to be drawn throughthe outlet port outwardly from the housing, wherein the outlet portincludes an airflow shielding element configured to contain themicrowave radiation within the heating chamber.
 2. The device of claim1, further comprising an aerosol precursor delivery arrangement operablyengaged with the heating chamber and configured to direct the aerosolprecursor composition to the heating chamber from a reservoir configuredto contain the aerosol precursor composition therein and in fluidcommunication with the aerosol precursor delivery arrangement.
 3. Amethod of making an aerosol delivery device, the method comprising:operably engaging a microwave radiation emitting device with a heatingchamber configured to receive an aerosol precursor composition therein,the microwave radiation emitting device comprising a magnetron extendingat least partially about the heating chamber and being configured toheat the aerosol precursor composition with microwave radiation emittedthereby to form an aerosol from the aerosol precursor composition; andengaging the heating chamber with a housing having an outlet port suchthat the outlet port is in fluid communication with the heating chamber,and such that the heating chamber is responsive to a suction applied tothe outlet port for the aerosol to be drawn through the outlet portoutwardly from the housing, wherein the outlet port includes an airflowshielding element configured to contain the microwave radiation withinthe heating chamber.
 4. The device of claim 1, wherein the magnetron isdisposed within an enclosure configured to substantially surround theheating chamber.
 5. The device of claim 4, further comprising two ormore reservoirs, wherein each reservoir is configured to contain adistinct aerosol precursor composition therein, wherein each of the twoor more reservoirs is in fluid communication with the aerosol precursordelivery arrangement and co-operable therewith for the aerosol precursordelivery arrangement to direct any of the distinct aerosol precursorcompositions from the respective one of the two or more reservoirs tothe heating chamber.
 6. The device of claim 5, further comprising anairflow channel defined within the housing or the enclosure, andconfigured to allow airflow between the heating chamber and ambient airexternal to the housing or the enclosure.
 7. The device of claim 6,wherein the airflow channel includes an airflow shielding elementconfigured to cooperate with the enclosure to contain the microwaveradiation within the enclosure.
 8. The device of claim 1, comprising ahose member having engaging proximal end engaged with the outlet portand an opposing distal end engaged with a mouthpiece element, themouthpiece element and the hose member being in fluid communication withthe heating chamber via the outlet port so as to receive the aerosoltherefrom in response to suction applied to the mouthpiece element. 9.The device of claim 1, comprising a controller element in communicationbetween the microwave radiation emitting device and a sensing element incommunication with the aerosol precursor composition within the heatingchamber, the sensing element being configured to sense a temperature ofthe aerosol precursor composition within the heating chamber, thecontroller element being responsive to the sensed temperature toregulate the microwave radiation output by the magnetron to heat theaerosol precursor composition within the heating chamber to a maximumdesired temperature.
 10. The device of claim 1, wherein the aerosolprecursor composition is selected from the group consisting of a liquid,a gel, a solid, a capsule, a colloid, a suspension, a botanical, and acombination thereof.
 11. The device of claim 10, wherein one componentof the aerosol precursor composition is configured to preventsuperheating of the aerosol precursor composition.
 12. The device ofclaim 1, comprising a wick engaged with the heating chamber, the wickbeing in communication with the aerosol precursor composition, whereinthe magnetron is configured to heat the wick such that an amount of theaerosol formed thereby is proportional to the an amount of the aerosolprecursor composition wicked by the wick.
 13. The device of claim 1,wherein the heating chamber comprises a first heating sub-chamber and asecond heating sub-chamber, one of the first and second heatingsub-chambers having a greater capacity for the aerosol precursorcomposition than the other, and wherein the first and second heatingsub-chambers are in fluid communication with the outlet port via aselector element, the selector element being responsive to the suctionapplied through the outlet port to direct the aerosol to the outlet portfrom the selected one of the first and second heating sub-chambers, anamount of the aerosol corresponding to a magnitude of the suction. 14.The device of claim 1, comprising an aerosol precursor processing unitin fluid communication with the heating chamber and configured topre-heat the aerosol precursor composition to a pre-heat temperature,the pre-heat temperature being less than a maximum desired temperaturefor forming the aerosol from the aerosol precursor composition, prior tothe pre-heated aerosol precursor composition being directed to theheating chamber.
 15. The device of claim 14, wherein the aerosolprecursor processing unit comprises a heating element or an aerosolforming element configured to interact with the aerosol precursorcomposition.
 16. The device of claim 1, comprising an aerosol precursorprocessing unit in communication with the heating chamber and configuredto pre-heat a substrate material having the aerosol precursorcomposition associated therewith to a pre-heat temperature, the pre-heattemperature being less than a maximum desired temperature for formingthe aerosol from the aerosol precursor composition, prior to thepre-heated substrate material being directed to the heating chamber. 17.The device of claim 1, comprising an aerosol precursor processing unitin communication with the heating chamber and configured to pre-heat amembrane comprised of the aerosol precursor composition to a pre-heattemperature, the pre-heat temperature being less than a maximum desiredtemperature for forming the aerosol from the aerosol precursorcomposition, prior to the pre-heated membrane being directed to theheating chamber.
 18. The method of claim 3, further comprising engagingan aerosol precursor processing unit in fluid communication with theheating chamber, the aerosol precursor processing unit being configuredto pre-heat a substrate material having the aerosol precursorcomposition associated therewith to a pre-heat temperature, the pre-heattemperature being less than a maximum desired temperature for formingthe aerosol from the aerosol precursor composition, prior to thepre-heated substrate material being directed to the heating chamber. 19.The method of claim 3, further comprising engaging an aerosol precursordelivery arrangement in fluid communication with the heating chamber,the aerosol precursor delivery arrangement being configured to directthe aerosol precursor composition to the heating chamber from areservoir having the aerosol precursor composition therein.
 20. Themethod of claim 3, further comprising engaging an aerosol precursorprocessing unit in fluid communication with the heating chamber, theaerosol precursor processing unit being configured to pre-heat amembrane comprising of the aerosol precursor composition to a pre-heattemperature, the pre-heat temperature being less than a maximum desiredtemperature for forming the aerosol from the aerosol precursorcomposition, prior to the pre-heated membrane being directed to theheating chamber.
 21. The method of claim 3, further comprising disposingthe magnetron within an enclosure configured to substantially surroundthe heating chamber.
 22. The method of claim 21, further comprisingforming two or more reservoirs within the housing, wherein eachreservoir includes a distinct aerosol precursor composition therein,wherein each of the two or more reservoirs is in fluid communicationwith the aerosol precursor delivery arrangement and is co-operabletherewith for the aerosol precursor delivery arrangement to direct anyof the distinct aerosol precursor compositions from the respective oneof the two or more reservoirs to the heating chamber.
 23. The method ofclaim 22, further comprising defining an airflow channel within thehousing or the enclosure, the airflow channel being configured to allowairflow between the heating chamber and ambient air external to thehousing or the enclosure.
 24. The method of claim 23, further comprisingdisposing an airflow shielding element in the airflow channel, theairflow shielding element being configured to cooperate with theenclosure to contain the microwave radiation within the enclosure. 25.The method of claim 3, further comprising engaging a proximal end of ahose member with the outlet port and engaging an opposing distal end ofthe hose member with a mouthpiece element, the mouthpiece element andthe hose member being in fluid communication with the heating chambervia the outlet port so as to receive the aerosol therefrom in responseto suction applied to the mouthpiece element.
 26. The method of claim 3,further comprising operably engaging a controller element between themicrowave radiation emitting device and a sensing element incommunication with the aerosol precursor composition within the heatingchamber, the sensing element being configured to sense a temperature ofthe aerosol precursor composition within the heating chamber, and thecontroller element being configured to be responsive to the sensedtemperature to regulate the microwave radiation output by the magnetronto heat the aerosol precursor composition within the heating chamber toa maximum desired temperature.
 27. The method of claim 3, furthercomprising selecting the aerosol precursor composition from the groupconsisting of a liquid, a gel, a solid, a capsule, a colloid, asuspension, a botanical, and a combination thereof.
 28. The method ofclaim 27, wherein selecting the aerosol precursor composition furthercomprises selecting the aerosol precursor composition such that onecomponent thereof is configured to prevent superheating of the aerosolprecursor composition.
 29. The method of claim 3, further comprisingengaging a wick with the heating chamber such that the wick is incommunication with the aerosol precursor composition, wherein themagnetron is configured to heat the wick such that an amount of theaerosol formed thereby is proportional to the an amount of the aerosolprecursor composition wicked by the wick.
 30. The method of claim 3,further comprising defining, in the heating chamber, a first heatingsub-chamber and a second heating sub-chamber, one of the first andsecond heating sub-chambers having a greater capacity for the aerosolprecursor composition than the other, and wherein the first and secondheating sub-chambers are configured to selectively be in fluidcommunication with the outlet port via a selector element, the selectorelement being responsive to the suction applied through the outlet portto direct the aerosol to the outlet port from the heating sub-chamber inselective communication therewith, an amount of the aerosolcorresponding to a magnitude of the suction.
 31. The method of claim 3,further comprising engaging an aerosol precursor processing unit influid communication with the heating chamber, the aerosol precursorprocessing unit being configured to pre-heat the aerosol precursorcomposition to a pre-heat temperature, the pre-heat temperature beingless than a maximum desired temperature for forming the aerosol from theaerosol precursor composition, prior to the pre-heated aerosol precursorcomposition being directed to the heating chamber.
 32. The method ofclaim 31, wherein engaging the aerosol precursor processing unitcomprises arranging a heating element or an aerosol forming element tointeract with the aerosol precursor composition prior to the pre-heatedaerosol precursor composition being directed to the heating chamber.